Decorative masonry system

ABSTRACT

A decorative masonry system includes a first block having a first body portion and a first plurality of edges and a second block having a second body portion and a second plurality of edges. A first gutter is defined by a portion of the first plurality of edges, and a second gutter is defined by a portion of the second plurality of edges. The decorative masonry system further includes mastic configured to operably couple the first and second blocks to a substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Patent Application No. 62/700,549, entitled “DECORATIVEMASONRY SYSTEM,” filed Jul. 19, 2018, the entire disclosure of which isincorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to a decorative masonry system,and more specifically to a tight-seam decorative masonry system.

BACKGROUND OF THE DISCLOSURE

Currently, decorative masonry systems including faux stones requireapplication of a mastic to the rear surface of each block in the system.When the block is pressed against a wall or surface, the masticoverflows around the edges of the stone, requiring the installer toremove the excess mastic by hand.

SUMMARY OF THE DISCLOSURE

According to some aspects of the present disclosure, a decorativemasonry system includes a first block having a first body portion and afirst plurality of edges. The first block includes a first engagementfeature. A second block has a second body portion and a second pluralityof edges. The second block includes a second engagement feature. A firstgutter is defined by a portion of the first plurality of edges, and asecond gutter is defined by a portion of the second plurality of edges.The decorative masonry system further includes mastic configured tooperably couple the first and second blocks to a substrate. The firstand second gutters are configured to receive a portion of the mastic toallow the first block to engage the second block in a surface-to-surfaceengagement.

According to some aspects of the present disclosure, a decorativemasonry system includes a block having a body portion and a plurality ofedges. The body portion includes a front surface. Each edge of theplurality of edges includes an edge surface. A portion of the pluralityof edges includes an angled surface. A gutter is defined by each angledsurface of the plurality of edges. The decorative masonry system furtherincludes mastic configured to operably couple a rear surface of theblock to a substrate. At least a portion of the mastic is configured toflow into the gutter.

According to some aspects of the present disclosure, a method for makinga decorative masonry system includes a step of providing a moldconfigured to shape a decorative masonry block. The decorative masonryblock has a body portion and an engagement feature. A plurality of edgesof the decorative masonry block define a gutter. The method may furtherinclude a step of forming a first block and a second block from aformable material using the mold. The method may further include a stepof applying mastic to a rear surface of each of the first block and thesecond block. The method includes a step of placing the first block on asubstrate so that the mastic is positioned between the rear surface ofthe first block and the substrate. The method may further include a stepof displacing the mastic along the plurality of edges of the bodyportion and the engagement feature of the first block. The gutter isconfigured to receive displaced mastic to prevent the displaced masticfrom engaging a surface-to-surface seam defined between the first andsecond blocks.

These and other features, advantages, and objects of the presentdisclosure will be further understood and appreciated by those skilledin the art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front elevation view of a decorative masonry block,according to an aspect of the device;

FIG. 1B is a front elevation view of a decorative masonry block havingan engagement feature, according to an aspect of the device;

FIG. 2 is a cross-sectional view of the decorative masonry block of FIG.1B taken along line II-II;

FIG. 3 is a front elevation view of a decorative masonry systemcomprising the decorative masonry blocks of FIG. 1B;

FIG. 4 is a cross-sectional view of the decorative masonry system ofFIG. 3 taken along line IV-IV;

FIG. 4A is a zoomed-in view of FIG. 4 as indicated by area IVA; and

FIG. 5 is a flow diagram illustrating a method for making and assemblinga decorative masonry system.

DETAILED DESCRIPTION

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the disclosure as oriented in FIGS. 1A and 1B.However, it is to be understood that the disclosure may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary examples of the inventiveconcepts defined in the appended claims. Hence, specific dimensions andother physical characteristics relating to the examples disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

As required, detailed examples of the present disclosure are disclosedherein. However, it is to be understood that the disclosed examples aremerely exemplary of the disclosure that may be embodied in various andalternative forms. The figures are not necessarily to a detailed designand some schematics may be exaggerated or minimized to show functionoverview. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present disclosure.

In this document, relational terms, such as first and second, top andbottom, and the like, are used solely to distinguish one entity oraction from another entity or action, without necessarily requiring orimplying any actual such relationship or order between such entities oractions. The terms “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus. An element preceded by “comprises” does not, without moreconstraints, preclude the existence of additional identical elements inthe process, method, article, or apparatus that comprises the element.

As used herein, the term “and/or,” when used in a list of two or moreitems, means that any one of the listed items can be employed by itself,or any combination of two or more of the listed items can be employed.For example, if a composition is described as containing components A,B, and/or C, the composition can contain A alone; B alone; C alone; Aand B in combination; A and C in combination; B and C in combination; orA, B, and C in combination.

Referring to FIGS. 1A-4A, reference numeral 10 generally relates to adecorative masonry system including a first block 14 having a first bodyportion 18 and a first plurality of edges 22 and a second block 26having a second body portion 30 and a second plurality of edges 34. Afirst gutter 38 is defined by a portion of the first plurality of edges22, and a second gutter 42 is defined by a portion of the secondplurality of edges 34. The decorative masonry system 10 further includesmastic 46 configured to operably couple the first and second blocks 14,26 to a substrate 50.

Referring now to FIG. 1A, according to some examples of the device, oneof the first and second blocks 14, 26 is illustrated having therespective body portion 18, 30. While FIGS. 1A and 1B illustrate asingle member of the decorative masonry system 10, this illustratedmember is indicative of the first and second blocks 14, 26, which aresubstantially similar. In these FIGS. 1A and 1B, pairs of referencenumbers are used to indicate some corresponding features that arepresent on each of the first and second blocks 14, 26. Each body portion18, 30 includes a front surface 60 having various protrusions 64configured to resemble various types of stone masonry. The protrusions64 may be arranged in any pattern across the front surface 60. The bodyportion 18, 30 further includes the plurality of edges 22, 34 formingthe perimeter of the block 14, 26. In some examples, each of the edges22, 34 may be generally linear and positioned to form right angles(e.g., angles measuring about 90°). In other examples, the edges 22, 34may be positioned to form any other angle (rectilinear or tessellatedpolygons, etc.) configured to allow the block 14, 26, in asurface-to-surface engagement, to sit flush with another block 14, 26when installed (see FIG. 3).

Referring now to FIG. 1B, according to some examples, one of the firstand second blocks 14, 26 is illustrated having the respective bodyportion 18, 30 and one of a first and second plurality of engagementfeatures 68, 72, respectively. These engagement features 68, 72 extendfrom the body portion 18, 30 and cause the first and second block 14, 26to have a non-rectangular shape. In some examples, it is contemplatedthat the block 14, 26 may have only one engagement feature 68, 72.Similar to the block 14, 26 shown in FIG. 1A, the body portion 18, 30and the plurality of engagement features 68, 72 includes the frontsurface 60 having the protrusions 64 configured to resemble stonemasonry. The protrusions 64 may be arranged in any pattern across thefront surface 60. The body portion 18, 30 and the plurality ofengagement features 68, 72 further include the plurality of edges 22, 34forming the perimeter of the block 14, 26. In some examples, each of theedges 22, 34 may be generally linear and positioned to form right angles(e.g., angles measuring about 90°). In other examples, the edges 22, 34may be positioned to form any other angle configured to allow the block14, 26 to sit flush with another block 14, 26 when installed (see FIG.3).

Referring now to FIG. 2, a cross-sectional view of one of the first andsecond blocks 14, 26 is shown having the front surface 60 and a rearsurface 80. The plurality of edges 22, 34 includes an edge surface 84and an angled surface 88. The edge surface 84 extends substantiallyperpendicular to the front surface 60 and is integrally formed with theangled surface 88. The angled surface 88 extends away from the edgesurface 84 at a predetermined angle A towards the rear surface 80. Inother words, the angled surface 84 may extend rearward of the frontsurface 60 toward the rear surface 80 of each of the respective blocks14, 26. The angle A may be within a range of from about 5° to about 85°measured from the edge surface 84. For example, the angle A may be about5°, about 10°, about 15°, about 20°, about 25°, about 30°, about 35°,about 40°, about 45°, about 50°, about 55°, about 60°, about 65°, about70°, about 75°, about 80°, or about 85° or any value or range of valuestherebetween. The angle A may be from about 30° to about 75°, from about50° to about 65°, or from about 55° to about 60°. The angled surface 88may be included on each edge of the plurality of edges 22, 34 in someexamples, partially forming a continuous first or second gutter 38, 42around the perimeter of the block 14, 26. In other examples, the angledsurface 88 may be included on only a portion of edges of the pluralityof edges 22, 34, partially forming a discontinuous first or secondgutter 38, 42. Where the gutter 38, 42 is discontinuous, the angledsurfaces 88 are positioned so that at least one gutter 38, 42 is presentbetween engaging first and second blocks 14, 26. Accordingly, each seam,or engagement, 94 of the decorative masonry system 10 will typicallyinclude at least one angled surface 88 that corresponds to a gutter 38,42. The gutter 38, 42 is configured to catch overflowing mastic 46 fromthe rear surface 80 without allowing the mastic 46 to reach the edgesurface 84, as shown in FIG. 4. By retaining the mastic 46 in thegutters 38, 42, the mastic 46 is prevented from reaching and extendingbetween the edge surface 84 of the first and second blocks 14, 26. Inthis manner, the mastic 46 does not interfere with thesurface-to-surface engagement of the edge surface 84 of the first andsecond blocks 14, 26.

Referring now to FIG. 3, the first block 14 and the second block 26 maybe positioned together so that one of the first engagement features 68of the first block 14 is aligned with one of the second engagementfeatures 72 of the second block 26. When the blocks 14, 26 arepositioned together, the first plurality of edges 22 is flush with, andis substantially in a surface-to-surface engagement with, the secondplurality of edges 34 where the blocks 14, 26 touch. This creates aseamless interface to match the seamless aesthetic of the protrusions 64of the blocks 14, 26. It is contemplated that any number of blocks 14,26 may be used to form the decorative masonry system 10 withoutdeparting from the scope of the present disclosure.

Referring to FIGS. 4 and 4A, a cross-sectional view of the first andsecond blocks 14, 26 positioned together in the decorative masonrysystem 10 is illustrated having the front surfaces 60 aligned. Themastic 46 is applied to the rear surface 80 of the first and secondblocks 14, 26 and is trapped between the rear surfaces 80 and thesubstrate 50. The first engagement feature 68 of the first block 14 iscoupled with the second engagement feature 72 of the second block 26 sothat at least one of the first plurality of edges 22 is substantiallyflush with one of the second plurality of edges 34. When one of thefirst plurality of edges 22 is positioned flush with one of the secondplurality of edges 34, the angled surfaces 88 of the respective edges22, 34 are aligned so that the first gutter 38 is in communication withthe second gutter 42 to form a channel 90. The channel 90 is configuredto receive mastic 46 that leaks or is displaced from the application ofthe blocks 14, 26 to the substrate 50. Further, when one of the firstplurality of edges 22 is positioned flush with one of the secondplurality of edges 34, the edge surfaces 84 of the respective edges 22,34 are positioned to form a tight and close fitting engagement 94,providing a tight and close fitting relationship between the blocks 14,26 with surface-to-surface engagement. In various examples, the edgesurfaces 84 of one of the blocks 14, 26 may be positioned to form atight and close fitting engagement 94 with a second, or base, substrate98 such as, for example, a top surface of a horizontal foundation wall.This engagement may service to hide, conceal, or otherwise obscure thelocation of the seam 94 between the first and second blocks 14, 26. Itwill be understood that the tight and close fitting engagement 94 may bein any location along the engagement 94 around the blocks 14, 26 inorder to form the desired design with the blocks 14, 26 for thedecorative masonry system 10.

To assemble the decorative masonry system 10, mastic 46 is applied tothe rear surface 80 of each of the first and second blocks 14, 26. Thefirst and second blocks 14, 26 are placed against the substrate 50,trapping the mastic 46 between the rear surface 80 and the substrate 50.When pressure is applied to the respective front surfaces 60 to securethe first and second blocks 14, 26 to the substrate 50, the mastic 46overflows along arrows B into the respective first or second gutter 38,42. The gutters 38, 42 trap the mastic 46 overflowing without damagingthe surface-to-surface engagement of the decorative masonry system 10.

When assembling conventional masonry systems, mastic overflows when theblocks are applied to the substrate. The mastic then collects on theedges of the blocks and must be manually removed. The inaccuracy of theremoval may cause gaps between the blocks, causing seams to show andruining the illusion of an authentic stone façade. The removal is alsolabor intensive and costly to do properly to achieve the seamless look.

With the proposed decorative masonry system 10, the blocks 14, 26 can bemolded for any type of stone façade (e.g., brick, flagstone, etc.) toprovide a seamless appearance. The relief pattern of the blocks 14, 26further increases the seamless aesthetic, creating an illusion ofindividual stacked pieces of stone masonry.

Referring now to FIG. 5, with continued reference to FIGS. 1A-4A, amethod 100 for making a decorative masonry system 10 is provided thatcomprises a step 104 of providing a mold configured to shape adecorative masonry block 14, 26. The decorative masonry block 14, 26 hasa body portion 18, 30 and an engagement feature 68, 72. A plurality ofedges 22, 34 of the decorative masonry block 14, 26 defines a gutter 38,42. The method 100 may further include a step 108 of forming a firstblock 14 and a second block 26 from material using the mold. Next is astep 112 of applying mastic 46 to rear surface 80 of each of the firstblock 14 and the second block 26. The method 100 may further include astep 116 of placing the first block 14 on a substrate 50 so that themastic 46 is positioned between the rear surface 80 of the first block14 and substrate 50. By pressing the first and second blocks 14, 26against the substrate 50, the mastic 46 is displaced around portions ofthe first and second blocks 14, 26 and toward or into the gutters 38, 42defined by the edges 22 (step 120). Next is a step 124 of placing thesecond block 26 on the substrate 50 so that the mastic 46 is positionedbetween the rear surface 80 of the second block 26 and the substrate 50and the second block 26 is aligned with the first block 14. One of theplurality of edges 34 of the second block 26 is engaged with one of theplurality of edges 22 of the first block 14 in surface-to-surfacecontact. It is contemplated that, although the steps are listed in aparticular order, they may be performed in any order or with two or moresteps being performed concurrently without departing from the scope ofthe present disclosure.

The decorative masonry system 10 disclosed herein provides a smallerrear surface 80 so to provide for the angled surface 88 to form thegutters 38, 42, and, in turn, the channel 90 for accumulating excessmastic 46. This mastic 46 can spread when the first and second blocks14, 26 are pressed against the substrate 50. By accumulating this excessmastic 46 in the channel 90, the seam 94 between the first and secondblocks 14, 26 remains a surface-to-surface engagement 94 that conceals,hides, and obscures the presence of the location of the engagement 94for the decorative masonry system 10.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

Furthermore, any arrangement of components to achieve the samefunctionality is effectively “associated” such that the desiredfunctionality is achieved. Hence, any two components herein combined toachieve a particular functionality can be seen as “associated with” eachother such that the desired functionality is achieved, irrespective ofarchitectures or intermedial components. Likewise, any two components soassociated can also be viewed as being “operably connected” or “operablycoupled” to each other to achieve the desired functionality, and any twocomponents capable of being so associated can also be viewed as being“operably coupleable” to each other to achieve the desiredfunctionality. Some examples of operably coupleable include, but are notlimited to, physically mateable and/or physically interacting componentsand/or wirelessly interactable and/or wirelessly interacting componentsand/or logically interacting and/or logically interactable components.Furthermore, it will be understood that a component preceding the term“of the” may be disposed at any practicable location (e.g., on, within,and/or externally disposed from the vehicle) such that the component mayfunction in any manner described herein.

As used herein, the term “about” means that amounts, sizes,formulations, parameters, and other quantities and characteristics arenot and need not be exact, but may be approximate and/or larger orsmaller, as desired, reflecting tolerances, conversion factors, roundingoff, measurement error and the like, and other factors known to those ofskill in the art. When the term “about” is used in describing a value oran end-point of a range, the disclosure should be understood to includethe specific value or end-point referred to. Whether or not a numericalvalue or end-point of a range in the specification recites “about,” thenumerical value or end-point of a range is intended to include twoembodiments: one modified by “about,” and one not modified by “about.”It will be further understood that the end-points of each of the rangesare significant both in relation to the other end-point, andindependently of the other end-point.

It is also important to note that the construction and arrangement ofthe elements of the disclosure as shown in the exemplary examples isillustrative only. Although only a few examples of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connectors or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system might beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary examples without departing from the spirit of thepresent innovations.

What is claimed is:
 1. A decorative masonry system comprising: a firstblock having a first body portion and a first plurality of edges,wherein the first block includes a first engagement feature; a secondblock having a second body portion and a second plurality of edges,wherein the second block includes a second engagement feature; a firstgutter defined by a portion of the first plurality of edges; a secondgutter defined by a portion of the second plurality of edges; and masticconfigured to operably couple the first and second blocks to asubstrate, wherein the first and second gutters are configured toreceive a portion of the mastic to allow the first block to engage thesecond block in a surface-to-surface engagement.
 2. The decorativemasonry system of claim 1, wherein the first and second engagementfeatures are integrally formed with one of the first and second bodyportions, respectively.
 3. The decorative masonry system of claim 2,wherein the first engagement feature of the first block is configured tomatingly couple with the second engagement feature of the second block.4. The decorative masonry system of claim 1, wherein each of the firstand second plurality of edges includes an edge surface positionedperpendicular to a front surface of the respective block of the firstand second blocks.
 5. The decorative masonry system of claim 4, whereinthe edge surface of the first block is configured to align with the edgesurface of the second block to form a seam that defines thesurface-to-surface engagement.
 6. The decorative masonry system of claim4, wherein each of the first and second plurality of edges furtherincludes an angled surface extending rearward of the respective edgesurface.
 7. The decorative masonry system of claim 6, wherein the angledsurface at least partially defines the respective gutter of the firstand second gutters.
 8. The decorative masonry system of claim 6, whereinthe angled surface is positioned at an angle from about 5° to about 85°measured from the edge surface.
 9. The decorative masonry system ofclaim 1, wherein the first gutter is aligned with the second gutter toform a channel that is configured to receive a portion of the mastic.10. A decorative masonry system comprising: a block having a bodyportion and a plurality of edges, wherein the body portion includes afront surface and each edge of the plurality of edges includes an edgesurface and a portion of the plurality of edges includes an angledsurface; a gutter defined by each angled surface of the plurality ofedges; and mastic configured to operably couple a rear surface of theblock to a substrate, wherein at least portion of the mastic isconfigured to flow into the gutter.
 11. The decorative masonry system ofclaim 10, wherein the block includes an engagement feature integrallyformed with the body portion and is surrounded by the plurality ofedges.
 12. The decorative masonry system of claim 10, wherein aplurality of protrusions extends from the front surface of the block,and further wherein the plurality of protrusions are configured toresemble masonry materials.
 13. The decorative masonry system of claim10, wherein the edge surface of each edge of the plurality of edges ispositioned perpendicular to the front surface of the block.
 14. Thedecorative masonry system of claim 10, wherein the angled surface ofeach edge of the plurality of edges is positioned at an angle from about5° to about 85° measured from the respective edge surface.
 15. Thedecorative masonry system of claim 10, wherein the angled surface ofeach edge of the plurality of edges is positioned at an angle from about30° to about 75° measured from the respective edge surface.
 16. Thedecorative masonry system of claim 10, wherein the edges of theplurality of edges define a continuous gutter extending about aperimeter of the block.
 17. The decorative masonry system of claim 10,wherein the edge surface of the block, when positioned at a lower edgeof the substrate, is configured to form a seam with a base substrate.18. A method for making a decorative masonry system, comprising stepsof: providing a mold configured to shape a decorative masonry block, thedecorative masonry block having a body portion and an engagementfeature, wherein a plurality of edges of the decorative masonry blockdefine a gutter; forming a first block and a second block from aformable material using the mold; applying mastic to a rear surface ofeach of the first block and the second block; placing the first block ona substrate so that the mastic is positioned between the rear surface ofthe first block and substrate; and displacing the mastic along theplurality of edges of the body portion and the engagement feature of thefirst block, wherein the gutter is configured to receive displacedmastic to prevent the displaced mastic from engaging asurface-to-surface seam defined between the first and second blocks. 19.The method for making a decorative masonry system of claim 18, furthercomprising the steps of: placing the second block on the substrate sothat the mastic is positioned between the rear surface of the secondblock and the substrate and the second block is aligned with the firstblock; and aligning one of the plurality of edges of the second block isengaged with one of the plurality of edges of the first block to definethe surface-to-surface seam.
 20. The method for making a decorativemasonry system of claim 18, wherein the step of displacing the masticalong the plurality of edges of the body portion and the engagementfeature of the first block includes applying pressure to a front surfaceof the first block.